MECH 3460 9460 Mechanical Systems Design 2 ASSIGNMENT 1 - Finite Element Design AnalysisJava

Java Python MECH 3460 9460

Mechanical Systems Design 2

You must complete the Week 1 Tutorial before starting this Assignment.

ASSIGNMENT 1 - Finite Element Design Analysis (FEA)

Part A - Bracket

Figure 1.0 – Bracket

Assignment 1 in MECH3460 9460 is broken into two parts. Part A is an extension of the first Tutorial and requires that you produce a report (maximum total of 20 pages for Parts A and B) that addresses the following criteria:

1.   Boundary Conditions:

Download the Bracket as described in Figure 1.0 (available on CANVAS) and apply the boundary conditions as defined below. The Bracket has been manufactured from a grade of Magnesium Alloy (any grade is fine). The Bracket needs to be redesigned for use in an aerospace application.

•   If the last digit of your SID is even, apply a pressure on the front face of the Bracket eyelet as shown in Figure 1.0 until the Yield Point of the magnesium alloy is reached (at any point).

•   If the last digit of your SID is odd, apply a pressure on the opposite face of the Bracket eyelet as shown in Figure 1.0 until the Yield Point of the magnesium alloy is reached (at any point).

•   If the second last digit of your SID is even, add a torque of 100 Nm to the main bore of the Bracket eyelet in an anticlockwise direction around the red dashed axis as shown in Figure 1.0.

•   If the second last digit of your SID is odd, add a torque of 100 Nm to the main bore of the Bracket eyelet in a clockwise direction around the red dashed axis to that shown in Figure 1.0.

•   In all the above cases, the bolt holes shown at the base of the Bracket must be constrained (but not the base bottom surface) as shown in Figure 1.0.

•   The relative position of the main bore and bolt holes must remain the same in your redesigned Bracket.

2.   Redesign of the Bracket:

Redesign the original Bracket to arrive at an optimised modified design for the bracket that best meets the following criteria:

a.   As illustrated in Figure 2.0, in no part of your redesigned Bracket is the Von Misses stress to be more than 75% of the Yield Point of the magnesium alloy (green line) or less than 25% of the Yield Point of the magnesium alloy (purple line).

Figure 2.0 - Typical Stress vs Strain Diagram

For a Magnesium Alloy

b.   In no part of your redesign Bracket is the deflection to be more than 1.0mm.

c.   Decreases the mass of your redesigned Bracket by as much as is possible whilst meeting the criteria noted previously.

3.   Manufacture:

•   The Bracket must be manufacturable by one of the methods noted in the Week 1 Tutorial (you must choose the method of manufacture to manufacture 10 off – No, metal 3D printing is not acceptable).

•   The Bracket is manufactured from a suitable grade of Magnesium Alloy (any grade is fine) that is compatible with the manufacturing method selected from the Week 1 Tutorial.

A summary which includes images, (approx. 500 words) discussing how your proposed redesigned Bracket will be manufactured.

4.   Engineering Drawing:

Produce an Engineering Drawing (one sheet) to AS1100 (A3 sheet in pdf format) of your final optimised design is also to be included in the Appendix to Part A. The drawing number of your Engineering Drawing is in the format SID_ 1 e.g., 590420319_ 1.

Part B – Your Choice

You must complete the Week 1 Tutorial before starting this Assignment.

Part B of Assignment 1 allows you to explore FEA-focused design on ONLY ONE additional sample from a collection of the two samples listed. Part B of Assignment  1 also requires that you produce a report (maximum total of 20 pages for Parts A and B) that addresses one of the follow two samples:

Sample 1: Vertical Post

Figure 2.0 – Vertical Post (Not to Scale)

The vertical post shown in Figure 2.0 is made up of a low carbon mild steel 250mm Parallel Flange Channel (PFC) 1500mm in length that is centrally located and welded to a horizontal base plate (500mm x 340mm x 25mm thick) also manufactured from low carbon mild steel (you are free to select a grade that is suitable for your design).

Your goal is to reinforce this connection by adding webs (wherever needed) and bolt holes (16mm in diameter) at locations on the plate that are advantageous in minimising stress and distortion.

The base plate is to be held in place only by the bolt holes that you have defined in terms of their size and location. Assume that the vertical post and base plate are welded together and require no analysis.

Forces Acting on Vertical Post:

1.    If the last digit of your SID is even, a force of 10kN is imposed in the direction of the blue and green arrows on the black surface.

2.    If the last digit of your SID is odd, a force of 10kN is imposed in the direction of the red and orange arrows on the black surface.

3.    If the second last digit of your SID is even, an additional force of 10kN is imposed in the direction of the purple arrow on the black surface.

4.    If the second last digit of your SID is odd, an additional force of 10kN is imposed in the direction of the white arrow on the black surface.

The aim of this part of the Assignment is to arrive at a suitable modified design for the post assembly that best meets all of the following criteria:

a.   The Von Misses stress in any part of the post assembly must lie between 50% and 90% of the Yield Point of the material.

b.   The maximum amount of deflection of the post assembly in any direction must not exceed 5.0mm.

c.   The weight of the of the post assembly must be reduced by at least 20% from its original weight.

Sample 2: L Shaped Bracket

 

Figure 4.0

L – Shaped Bracket

Sample 2 is an L-shaped bracket that needs to be stiffened and reinforced to carry forces at the holes shown.

1. Four mounting holes are shown on the vertical side of the bracket to fix it to a rigid wall, but you may choose to add and modify the locations for these holes.

2. You are required to modify the shape and thickness of this bracket such that with the loads indicated its deflection is reduced by a factor of 10.

3. The modifications to the design of this bracket must be kept practical, simple and light (mass may increase by no more than 50% of the original bracket).

4. You may add webs, welds, bosses, holes and alter plate thickness.

5. The bracket is made from low carbon steel (you are free to select a grade that is suitable for your design).

Forces Acting on Vertical Post:

1.  If the last digit of your SID is even, a force of 1.1kN is imposed in the direction of the blue and red arrows.

2. If the last digit of your SID is odd, a force of 1.1kN is imposed in the direction of the blue and green arrows.

3. If the second last digit of your SID is even, a force of 1.1kN is imposed in the direction of the blue and black arrows. Note: You must add the middle hole to the SolidWorks model supplied.

4. If the second last digit of your SID is odd, a force of 1.1kN is imposed in the direction of the purple and black arrows. Note: You must add the middle hole to the SolidWorks model supplied